CLARK FORKLIFT SM-730 WPX45 SERVICE MANUAL

SM-730 WPX45

Service Manual

November 2013

[cLqRK]' THE FORKLIFT

Technical Publications Lexington, KY 40510 www.Clarkmhc.com Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

WARNING Do not operate this truck unless you have been autho­ rized and trained to do so, and have read all warnings and instructions in Operator's Manual and on this truck.

Do not operate this truck until you have checked its condition. Give special attention to tires, horn, battery, controller, lift system, brakes, steering mechanism, guards and safety devices.

Operate truck only from designated operating position.

Do not carry passengers. Keep feet clear of truck and wear foot protection.

Observe applicable traffic regulations. Yield right of way to pedestrians. Slow down and sound horn at cross aisles and wherever vision is obstructed.

Start, stop, travel, steer and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause truck to slide or overturn. Use special care when traveling without load as the risk of overturn may be greater.

Always look in direction of travel. Keep a clear view, and when load interferes with visibility, travel with load trailing.

Use special care when operating on ramps travel slowly, and do not angle or turn. Travel with load downhill.

Do not handle loads which are higher than the load backrest or load backrest extension unless load is secured so that no part of it could fall backward.

Before lifting, be sure load is centered, forks are com­ pletely under load, and load is as far back as possible against load backrest.

When leaving truck, neutralize travel control, fully lower lifting mechanism and set brake. When leaving truck unattended, also shut off power.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

(CIARKr

TABLE OF CONTENTS Section

Page

1 DESCRIPTION ................................................... 1-1 1-1. INTRODUCTION. ..................................... 1-1 1-2. GENERAL DESCRIPTION . ...................... 1-1 1-3. SAFETY FEATURES................................ 1-2 2 OPERATION ....................................................... 2-1 2-1. GENERAL................................................. 2-1 2-2. OPERATING PRECAUTIONS.................. 2-1 2-3. BEFORE OPERATION ............................. 2-1 2-4. GENERAL CONTROL OPERATION. ....... 2-4 2-5. DRIVING AND STOPPING PROCEDURES. 2-4 2-6. BELLY-BUTTON SWITCH. ....................... 2-4 2-7. STEERING ARM GAS SPRING. .............. 2-5 2-8. LIFT AND LOWER CONTROLS............... 2-5 2-9. LOADING AND UNLOADING. .................. 2-5 2-10. PARKING. ................................................. 2-5 3 PLANNED MAINTENANCE ................................ 3-1 3-1. GENERAL................................................. 3-1 3-2. MONTHLY AND QUARTERLY CHECKS. 3-1 3-3. BATTERY CARE. ..................................... 3-1 3-3.1. General ..................................................... 3-1 3-3.2. Safety Rules ............................................. 3-2 3-3.3. Battery Care and Charging ....................... 3-2 3-3.4. Battery Cleaning ....................................... 3-2 3-3.5. MAINTENANCE FREE BATTERIES ........ 3-3 3-4. CHARGING BATTERIES.......................... 3-3 3-5. LUBRICATION.......................................... 3-4 4 TROUBLESHOOTING........................................4-1 4-1. GENERAL. ............................................... .4-1 4-2. CONTROLLER TROUBLESHOOTING ... .4-4 4-2.1. Zapi Handset ........................................... .4-4 4-2.2. Fault Detection......................................... .4-4 4-2.3. Testing Truck Operation........................... .4-4 4-2.4. Settings and Adjustments ........................ .4-5 5 STEERING ARM, CONTROL HEAD AND COMPARTMENT ................................................ 5-1 5-1. CONTROL HEAD ..................................... 5-1 5-1.1. Control Head Removal ............................. 5-1 5-1.2. Control Head Installation .......................... 5-2 5-1.3. Cap Assembly Removal. .......................... 5-3 5-1.4. Cap Assembly Installation. ....................... 5-3 5-1.5. Belly-Button Switch Replacement ............. 5-3 5-1.6. Horn Switch Replacement. ....................... 5-4 5-1.7. Lift and Lower Switch Replacement .........5-5 5-1.8. Speed Potentiometer Replacement. ......... 5-6 5-2. STEERING ARM ...................................... 5-6 5-2.1. Return Spring Replacement...................... 5-6 5-2.2. Steering Arm Removal. ............................. 5-6 5-2.3. Steering Arm Installation. .......................... 5-6

SM-730

SectionPage

THE fORKLln

5-3. COMPARTMENT COVERS...................... 5-6 5-3.1. Removal.................................................... 5-6 5-3.2. Installation................................................. 5-6 6 BRAKE SERVICING ........................................... 6-1 6-1. BRAKES. .................................................. 6-1 6-1.1. Air Gap Adjustment................................... 6-1 6-1.2. Stopping Distance Adjustment... ............... 6-2 6-1.3. Brake Assembly Replacement.. ................ 6-2 7 TRANS, DRIVE WHEEL, LOAD WHEEL ........... 7-1 7-1. Drive Wheel. ............................................. 7-1 7-2. Transmission. ........................................... 7-1 7-3. Load Wheel............................................... 7-2 7-3.1. Removal.................................................... 7-2 7-3.2. Repair ...................................................... 7-2 7-3.3. Load Wheel Installation ............................ 7-2 8 ELEVATION SYSTEM SERVICING .................... 8-1 8-1. GENERAL.................................................8-1 8-2. Lift Linkage ...............................................8-1 8-2.1. Removal.................................................... 8-1 8-2.2. lnstallation ................................................. 8-1 8-3. Power Section and Fork Section .............. 8-1 8-3.1. Separating Power Section and Fork Section.............................................. 8-1 8-3.2. Fork Frame Repair.................................... 8-1 8-3.3. Carrier Frame Repair. ............................... 8-1 8-3.4. Mating Power Section and Fork Section...................................................... 8-1 9 HYDRAULIC SYSTEM SERVICING ..................9-1 9-1. LINES AND FITTINGS .............................9-1 9-2. HYDRAULIC PUMP, MOTOR, AND RESERVOIR ASSY ..................................9-1 9-2.1. Removal.................................................... 9-1 9-2.2. Disassembly and Reassembly .................. 9-3 9-2.3. lnstallation................................................. 9-3 9-2.4. Lift Cylinder ............................................... 9-3 10 ELECTRICAL COMPONENTS......................... 10-1 10-1. ELECTRICAL CONTROL PANEL .......... 10-1 10-1.1.Maintenance .......................................... 10-1 10-1.2.Cleaning ................................................ 10-1 10-1.3.Panel Removal. ..................................... 10-1 10-1.4.Panel Disassembly. ............................... 10-1 10-1.5.Panel Installation. .................................. 10-1 10-2. HORN REPLACEMENT ......................... 10-3 10-3. PUMP MOTOR. ...................................... 10-4 10-4. DRIVE MOTOR. ..................................... 10-4 10-4.1.Motor Removal ...................................... 10-4 10-4.2.Motor Repair .......................................... 10-4 10-4.3.Motor Installation ................................... 10-4 10-5. LIFT LIMIT SWITCH .............................. 10-6

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

[CIARKr

TABLE OF CONTENTS - Continued

THE FORKlln

10-5.1. Replacement10-6 10-5.2.Adjustment ............................................ 10-6 10-6. DEADMAN SWITCH .............................. 10-6 10-6.1.Replacement ......................................... 10-6

11 OPTIONAL EQUIPMENT ................................. 11-1 11-1. LOAD BACKREST.. ................................ 11-1 11-2. CASTERS .............................................. 11-1

LIST OF ILLUSTRATIONS Figure 1-1 1-2 2-1 2-2 2-3 2-4 2-5 3-1 4-1 4-2 4-3 4-4 4-5 4-6 5-1 5-2

Page Name Plate ................................................. 1-1 WPX45 Lift Truck ........................................ 1-1 Sample of Operator Check List ................... 2-3 Forward/Reverse Control ............................ 2-4 Pushbutton Switches................................... 2-4 Brake Actuation ........................................... 2-4 Belly-Button Switch ..................................... 2-5 Lubrication Diagram .................................... 3-5 Connecting the Handset.............................. 4-4 Zapi Handset.. ............................................. 4-5 Zapi Handset............................................... 4-9 Throttle Regulation .................................... 4-10 Zapi Handset.. ........................................... 4-11 Zapi Controller Connections...................... 4-13 Steering Arm ............................................... 5-1 Control Head ............................................... 5-2

Figure 5-3 5-4 5-5 6-1 7-1 7-2 8-1 9-1 9-2 9-3 10-1 10-2 10-3 10-4

Page Emergency Reverse Switch Assy ............... 5-3 Cap Assembly ............................................. 5-4 Left Lift/Lower Switch Assy ......................... 5-5 Brake Assembly .......................................... 6-1 Transmission, Motor, Brake Assy ................ 7-1 Wheel Assembly ......................................... 7-2 Frame (Sheet 1) .......................................... 8-2 Hydraulic System ........................................ 9-2 Pump and Motor Assembly ......................... 9-3 Lift Cylinder ................................................. 9-4 Electrical System ....................................... 10-2 Electrical Panel .... .. .. .... .. ...... ... .... ... .... ...... . 10-3 Transmission, Motor, Brake Assembly ................................................... 10-4 Drive Motor................................................ 10-5

LIST OF TABLES Table 2-1 3-1 3-2 3-3

ii

Page Operator Checks.......................................... 2-2 Monthly and Quarterly Inspection and Service Chart ........................................ 3-1 Recommended Lubricants ........................... 3-4 Lubrication Chart ......................................... 3-5

Page

Table 4-1 4-2 4-3 4-4 4-5

Troubleshooting Chart ................................. 4-1 Set Options .................................................. 4-5 Adjustments ................................................. 4-9 Parameter Adjustments ............................. 4-11 Zapi Controller Connector Pins.................. 4-13

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-730

(CIARKr THE fORK.LI n

SECTION 1 DESCRIPTION 1-1. INTRODUCTION.

forks raised or lowered. The lift truck must be pro­ tected from the elements.

This publication describes the 24 volt transistor WPX45 lift truck distributed by CLARK Material Han­ dling CO. Included are operating instructions, planned maintenance instructions, lubrication procedures, cor­ rective maintenance procedures and a complete parts list with part location illustrations.

The model number will be found on the name plate (Figure 1-1) along with the serial number, lifting capac­ ity, and load center. Figure 1-2 shows the locations of the truck's main components and controls.

I

Users shall comply with all requirements indicated in applicable OSHA standards and current edition of A.N.S.I. 856.1 Part II. By following these requirements and the recommendations contained in this manual, you will receive many years of dependable service from your WPX45 lift truck.

0

@jllimm�

0

Model Number I I Type

I I

I Capacity: PoW!da I Kllog111m I Truck Weight Without Battery II I Wlih Maximum Battery I II Battery Weight : II Maxlmum1 II Minimum I Battery Number

I

Serial Number

1-2. GENERAL DESCRIPTION. The self-propelled WPX45 truck, Figure 1-2, lifts and transports payloads up to 4500 pounds on rigid forks.

The forward and reverse motion is controlled by either of two controller levers mounted on the control head.

Stopping and turning is controlled by the steering arm.

Lift and Lower is controlled by pushbuttons on the con­ trol head. The battery powered lift truck is quiet and without exhaust fumes.

I I Maximum Amp Houra I

I Inch Imm

I I I I

Olrec! current Vohage

The reversible AC motor propels the lift truck in for­ ward or reverse direction throughout the available speed range. The WPX45 lift truck can be driven with

From the factory thla truck meets ANSIB58.1

0

27819111

I I I

0

Figure 1-1 Name Plate

CONTROL HEAD BATTERY INDICATOR KEY SWITCH BATTERY DISCONNECT LOAD WHEEL BATTERY COMPARTMENT

R6622

DRIVE WHEEL

CASTER

Figure 1-2 . WPX45 Lift Truck

SM-730

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

1-1

(CIARKr THE fORKlln

1-3. SAFETY FEATURES.

• Separately fused control circuits and power circuits.

The WPX45 is designed and engineered to provide maximum safety for operator and payload. Some of the safety features incorporated into the design are:

• Readily accessible horn button.

• Dead-man brake to apply the brake and cut off drive power when the steering arm is released.

• Belly-button switch to reverse truck should the oper­ ator accidentally pin himself against a wall or obstruction when backing up in slow speed.

• All control functions automatically return to "OFF" when released.

• Externally accessible quick-disconnect battery plug within operator's reach.

1-2

• Handle to provide a firm hand hold for operator.

• Flow control valve regulates maximum lowering speed within prescribed limits.

• Relief valve maintains hydraulic pressure within pre­ scribed limits.

• High visibility color scheme of truck provides visual alert of truck's presence.

• Battery Indicator • Casters

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-730

[CIARKr THE FORK11n

SECTION 2 OPERATION 2-1. GENERAL. This section gives detailed operating instructions for the WPX45 lift truck. The instructions are divided into the various phases of operations, such as operating lift, driving, and stopping. Routine precautions are included for safe operation.

2-2. OPERATING PRECAUTIONS. WARNING: Improper operation of the lift truck may result in operator injury, or load and/or lift truck damage. Observe the following precautions when operating the WPX45 lift truck.

The following safety precautions must be adhered to at all times.

• Do not operate this truck unless you have been trained and authorized to do so and have read all warnings and instructions in this manual and on the truck.

• All warnings and instructions must be read and understood before using the equipment.

• Do not overload truck. Check nameplate for load weight and load center information.

• Before lifting, be sure load is centered, forks are completely under load, and load is as far back as possible against load backrest.

• Do not handle loads which are higher than the load backrest unless load is secured so that no part of it could fall backward.

• When leaving truck, neutralize travel control. Fully lower lifting mechanism and set brake. When leaving truck unattended, turn off key switch and disconnect switch, remove key and disconnect battery.

2-3. BEFORE OPERATION Table 2-1 covers important inspection points on the WPX45 lift truck which should be checked prior to operation. Depending on use, some trucks may require additional checks.

Figure 2-1 shows a sample format for an Operator Checklist, which can be modified as necessary to fit your operation.

• Equipment must be inspected by a qualified person on a regular basis.

WARNING: Periodic maintenance of this truck by a QUALIFIED TECHNICIAN is required.

• Do not operate this truck until you have checked its condition. Give special attention to Tires, Horn, Bat­ teries, Controller, Lift System, Brakes, Steering Mechanism, Guards and Safety Devices

CAUTION:

• Operate truck only from designated operation posi­ tion. Wear foot protection. Do not carry passengers.

• Observe applicable traffic regulations. Yield right of way to pedestrians. Slow down and sound horn at cross aisles and wherever vision is obstructed.

• Start, stop, travel, steer and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause truck to slide or overturn. Use spe­ cial care when traveling without load as the risk of overturn may be greater.

• Always look in direction of travel. Keep a clear view, and when load interferes with visibility, travel with load or lifting mechanism trailing.

SM-730

A QUALIFIED SERVICE TECHNICIAN should check the truck monthly for proper lubrication, proper fluid levels, brake maintenance, motor maintenance and other areas specified in the SEC­ TION 3.

WARNING: If the truck is found to be unsafe and in need of repair, or contributes to an unsafe condition, report it immediately to the designated authority. Do not operate it until it has been restored to a safe operating condition. Do not make any unauthorized repairs or adjustments. All service must be performed by a qualified maintenance technician.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

2-1

(CIARKr THE FORKLln

ITEM

Transmission and hydraulic systems.

Forks Safety signs

Horn Steering Travel controls

2-2

Table 2-1 Operator Checks

PROCEDURE

ITEM

Check for signs of fluid leakage.

Wheels

Check for cracks and damage.

Check that warning labels, nameplate, etc., are in good condition and legible.

Check that horn sounds when operated.

Check for binding or looseness in steering arm when steering.

Check that speed controls on control head operate in all speed ranges in forward and reverse and that belly button switch functions.

Hydraulic controls Brakes

Deadman/ Parking brake Battery disconnect

Battery charge

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PROCEDURE

Check drive wheel for cracks or damage. Move truck to check load for freedom of rotation.

Check operation of lift and lower to their maximum positions.

Check that brakes actuate when steering arm is raised to upright position, and when lowered to horizontal position.

Check that steering arm raises to upright position when released and brake applies.

Check that battery can be disconnected and reconnected. Check for connector damage.

Check the battery indicator.

SM-730